You guys asked for it, so here it is. A worklog.
Case that started it all: Compaq SR1830NX
Take note of the crappy placement of the mesh venting.
I hadn't planned on a worklog, so you're missing a few steps. Flipped, chopped, and new top and front.
Much more airflow!
Getting the window cut very quickly, with no regard to perfection.
The original rear fan grill cut out and filed.
The first filing on the window complete.
Needs some work in some places, but needs primer to be sure.
Note the oak support beside the motherboard tray. This keeps the tray flat against the side panel. A majority of the case structure had been removed so this was necessary to keep the tray from flapping in the wind.
Closer shot showing how much cleaner the edges are compared to the original cut.
Test fitting the smoked plexi with the door. This became a huge problem as the door slides on and the window was too large due to the funky mesh. This made it so I couldn't get the window on with the plexi in. ARGHH. Fixed it by cutting off all the metal slides on the side panel, so it now attaches more akin to an Antec 300.